Services

The Purpose

The purpose is to get the maximum throughput or output for the minimum dollar. This is accomplished through (1) full utilization horsepower, (2) reduction of downtime and lost production, (3) lower maintenance costs (reduction of parts and labor), and (4) lower fuel consumption (Energy Cost).

How can we achieve the best profitability from engines and compressors?

Select a maintenance concept most suitable for each unit.

Breakdown

Scheduled (preventative time based)

Predictive (condition and performance based)

Where and how does the recip analysis fit in with the different maintenance concepts?

Breakdown Maintenance - A recip. analyzer can be used as a troubleshooting tool.

Scheduled Maintenance - This is determined by manufacturer’s recommendation, past experience and records of maintenance and operations. A. Recip. analyzer can be used to evaluate the performance and condition of the unit using the indicators it provides,between the scheduled intervals. B. I f 100% online reliability to required and scheduled (preventative) maintenance is most suitable, a recip. analyzer can be used to determine the scheduled intervals.

Predictive Maintenance - A set of performance and condition indicators, that point to specific needs for maintenance are monitored and trended. The maintenance or repair is scheduled to correct the failing parts or components.

The Reciprocating Analysis

Recip. analyzers gather and display five different inputs, relative to crank shaft position. These inputs provide indicators and actual data about the machines condition and performance. The inputs to the analyzer are:

pressure

vibration

ultrasonic

electrical

temperature

Listed below are the indicators and data obtained from the analyzer.

1. Pressure

Horse power developed or consumed per cylinder

Throughput of each compressor cylinder

Horse power loss due to compressor valves, cylinders, bottles and piping.

Ultrasonic converts high frequency (35 KHz to 45 KHz) airborne acoustics and mechanical energy that is undetectable to the human ear to an electrical signal. It compliments both the pressure and vibration trace as second indictor in diagnosing of components.

This can also be use for internal or external leak detection on Recycle valves, dump valve and PSVs.

4. Electrical

This signal is used to trouble shoot and monitor ignition systems.

Both primary and secondary can be checked for proper operations and failed components can be identified.

Note: The shielded plug wires need to be changed with normal plug wires to be able to analyze the secondary ignition. The pressure vibration ultrasonic and electrical events occur at a given time and duration relative to crank shaft rotation, any deviation indicates a potential problem.

5. Temperature

Pressure drops causing gas temperature change

Hotter or cooler than normal process temperatures

Valve temperatures indicate leaking valves

Temperatures indicating plugged or inefficient exchangers

The recip analysis program is an integral part of a good maintenance program for reciprocating equipment. It establishes a set of valid indicators to determine performance and condition of engines and compressors and often pin points to wearing, failing, and incorrectly used parts and components.

Note: Suction and discharge bottle pressure readings are only required for the initial analysis and if operating condition change significantly. However, this information is very important to evaluate pressure drops in the system. High pressure drop are inefficiencies that consume/waste horse power and therefore reduce the potential capacity of the compressor.

signatures of the events that take place during the four strokes, valve and ring action, check for compression leaks and any unusual vibration such as knocks.

cam and lifter operation

check reciprocating components for excessive clearance that causes high vibration and/or knocks (note: it can’t detect a normal worn sleeve bearing or bushing in the engine or compressor that doesn’t generate high vibration).

main bearing vibration; internal component looseness

Primary ignition data is collected to check and compare for proper operation and ignition timing where accessible.

Special vibration data is collected on the auxiliaries for analysis and trending.

Water Pump, Oil Pump, Fan, Bearings if accessible.

Visual inspection of the unit by an experienced technician is also performed; any issues found will be mentioned in the report so these potential problems can be addressed at the next scheduled down time.

This tool is very useful when preformed prior to scheduled services to see what is wearing out on the compressor of what components may fail between service intervals. These parts can be changed out and the service to prevent unscheduled down time between the service intervals.

Also a good indication of what units need to be overhauled prior to a turn around. This will allow you to focus on the units which need attention and save money on the units which are in good running condition.

Is also recommended to perform a full analysis on new or recently overhauled equipment to insurer that the equipment is performing as expected, and in a safe manner.

A savings estimate when performing a full engine/compressor analysis on a regular basis (2 analyses per year) increased run time by 1% on a unit that produces 5 mmscfd with gas priced at $5.00